Camry Repair Manual STARTING

Camry Repair Manual

B01153

Throttle CableClamp (A/T)

Battery Tray

CruiseControlActuatorConnector

Cruise Control Actuator

Cruise ControlCover

ClampHold Down Clamp

Starter CableStarter Connector

StarterBattery

STARTER

COMPONENTS

Starter Housing and Clutch Assembly

Idler Gear

Bearing

Stop Collar

Pinion GearCompression SpringSpring Retainer

Steel BallReturnSpring

Magnetic SwitchAssembly

–

STARTING (5S–FE) STARTER

Magnetic Switch Assembly

Terminal Nut

Wave WasherTerminal Insulator

O–Ring

Contact PlateTerminalBolt

Wave WasherTerminal NutTerminal Bolt

Contact PlateTerminal Insulator

ST03J–01 –

STARTING (5S–FE) STARTER

REMOVAL

2 w/ CRUISE CONTROL SYSTEM:

REMOVE CRUISE CONTROL ACTUATOR

(a) Disconnect the actuator connector and clamp

(b) Remove the 3 bolts, and disconnect the actuator with the bracket

(a) Disconnect the starter connector

(b) Remove the 2 bolts, throttle cable clamp (A/T) and starter

(c) Remove the nut, and disconnect the starter cable

Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

(a) Remove the nut, and disconnect the lead wire from themagnetic switch terminal.

ASSEMBLY AND GEAR

(a) Remove the 2 screws

Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)

(b) Remove these parts from the magnetic switch:

(1) Starter housing and clutch assembly(2) Return spring

(3) Idler gear(4) Bearing

Using a magnetic finger, remove the steel ball from the clutchshaft hole

P13528

–

STARTING (5S–FE) STARTER

(a) Remove the 2 screws and end cover from the field frame

Torque: 1.5 N·m (15 kgf·cm, 13 in.·lbf)

(b) Remove the O–ring from the field frame

(c) Using a screwdriver, hold the spring back and disconnectthe brush from the brush holder Disconnect the 4brushes, and remove the brush holder

NOTICE:

Check that the positive (+) lead wires are not grounded.

(a) Check the commutator for open circuit.

Using an ohmmeter, check that there is continuity tween the segments of the commutator

be-If there is no continuity between any segment, replace the mature

ar-(b) Check the commutator for ground

Using an ohmmeter, check that there is no continuity tween the commutator and armature coil core

be-If there is continuity, replace the armature

(a) Check the commutator for the dirty and burnt surfaces

If the surface is dirty or burnt, correct it with sandpaper (No.400)

or on a lathe

(b) Check for the commutator circle runout

(1) Place the commutator on V–blocks

(2) Using a dial gauge, measure the circle runout

Maximum circle runout: 0.05 mm (0.0020 in.)

If the circle runout is greater than maximum, correct it on a lathe

(c) Using vernier calipers, measure the commutator ter

diame-Standard diameter: 30.0 mm (1.181 in.) Minimum diameter: 29.0 mm (1.142 in.)

If the diameter is less than minimum, replace the armature

(d) Check that the undercut depth is clean and free of foreignmaterials Smooth out the edge

Standard undercut depth: 0.6 mm (0.024 in.) Minimum undercut depth: 0.2 mm (0.008 in.)

If the undercut depth is less than minimum, correct it with ahacksaw blade

Brush Holder Side

Field Flame Side

Length

Length

ST0019

–

STARTING (5S–FE) STARTER

3 INSPECT FIELD COIL

(a) Check the field coil for open circuit

Using an ohmmeter, check that there is continuity tween the lead wire and field coil brush lead

be-If there is no continuity, replace the field frame

(b) Check the field coil for ground

Using an ohmmeter, check that there is no continuity tween the field coil end and field frame

be-If there is continuity, repair or replace the field frame

Using vernier calipers, measure the brush length

Standard length: 15.5 mm (0.610 in.) Minimum length: 10.0 mm (0.394 in.)

If the length is less than minimum, replace the brush holder andfield frame

Check the brush spring load

Take the pull scale reading the instant the brush springseparates from the brush

Standard spring installed load:

1.2 kW 13.7 – 19.6 N (1.4 – 2.0 kgf, 3.0 – 4.4 lbf) 1.4 kW 17.6 – 23.5 N (1.8 – 2.4 kgf, 3.9 – 5.3 lbf)

Minimum spring installed load:

1.2 kW 9.8 N (1.0 kgf, 2.2 lbf) 1.4 kW 11.8 N (1.2 kgf, 2.6 lbf)

If the installed load is less than minimum, replace the brushsprings

No ContinuityOhmmeter

Check the brush holder insulation

Using an ohmmeter, check that there is no continuity tween the positive (+) and negative (–) brush holders

be-If there is continuity, repair or replace the brush holder

(a) Check the gear teeth on the pinion gear, idler gear andclutch assembly for wear or damage

If damaged, replace the gear or clutch assembly

If damaged, also check the ring gear of the flywheel/drive platefor wear or damage

(b) Check the clutch pinion gear

Hold the starter clutch and rotate the pinion gear clockwise, and check that it turns freely Try to rotate thepinion gear clockwise and check that it locks

counter-If necessary, replace the clutch assembly

(a) Check the pull–in coil for open circuit

Using an ohmmeter, check that there is continuity tween terminals 50 and C

be-If there is no continuity, check and replace the magnetic switch

(b) Check the hold–in coil for open circuit

Using an ohmmeter, check that there is continuity tween terminal 50 and the switch body

be-If there is no continuity, replace the magnetic switch

Turn the bearing by hand while applying inward force

If resistance is felt or the bearing sticks, replace the bearing.(See page ST–11)

(a) Disassemble the starter housing and the clutch assembly.(1) Mount a brass bar in a vise, and install the starterhousing and clutch assembly to the brass bar.

(2) Push down the pinion gear

(3) Using a plastic–faced hammer, tap down the stopcollar

(4) Using a screwdriver, pry out the snap ring

(5) Remove these parts:

Starter Housing

StarterClutch

CompressionSpring

ClutchShaft

B01230

SpringCompression

(4) Push down the pinion gear

(5) Using snap ring pliers, install a new snap ring

(6) Using pliers, compress the snap ring

(7) Check that the snap ring fits correctly

STARTING (5S–FE) STARTER

(8) Remove the starter housing and clutch assemblyfrom the brass bar

(9) Using a plastic–faced hammer, tap the clutch shaftand install the stop collar onto the snap ring

(a) Using SST, remove the bearing

(a) Using SST, remove the bearing

SST 09286–46011

(b) Using a press, press in a new bearing

4 REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS

(a) Remove the 3 bolts, end cover, gasket and plunger

(b) Using vernier calipers, measure the contact plate fordepth of wear

Maximum wear: 0.9 mm (0.035 in.)

If the depth of wear is greater than the maximum, replace thecontact plate

(c) Remove the terminal kit parts

(1) Using SST, loosen the terminal nuts

SST 09810–38140(2) Terminal C:

Remove the terminal nut, wave washer, terminal sulator (outside), O–ring, terminal bolt, contactplate and terminal insulator (inside)

in-(3) Terminal 30:

Remove the terminal nut, wave washer, terminal sulator (outside), packing, O–ring, terminal bolt,contact plate, terminal insulator (inside)

in-(d) Temporarily install these new terminal 30 kit parts:(1) Terminal insulator (inside)

(2) Contact plate(3) Terminal bolt(4) O–ring(5) Packing and terminal insulator (outside)Install the packing to the terminal insulator, andinstall them

(7) Terminal nut

NOTICE:

Be careful to install the terminal insulators (inside) and wave washers in the correct direction.

(f) Temporarily tighten the terminal nuts

(g) Tighten terminal nuts

(1) Put a wooden block on the contact plate and press

it down with a hand press

Dimensions of wooden block:

20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.) Press force:

981 N (100 kgf, 221 lbf) NOTICE:

Check the diameter of the hand press ram Then culate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied.

cal-Gauge pressure:

spe-(2) Using SST, tighten the nuts to the specified torque.SST 09810–38140

Torque: 17 N·m (173 kgf·cm, 13 ft·lbf) NOTICE:

If the nut is over tightened, it may cause cracks on the side of the insulator.

in-(h) Clean the contact surfaces of the remaining contact plateand plunger with a dry shop rag

(i) Reinstall the plunger, a new gasket and the end coverwith the 3 bolts

Torque: 2.5 N·m (26 kgf·cm, 23 in.·lbf)

ST03N–02 –

STARTING (5S–FE) STARTER

With battery connected as above with the clutch pinion gearout, disconnect the negative (–) lead from terminal C Checkthat the pinion gear remains out.

3 INSPECT CLUTCH PINION GEAR RETURN

Disconnect the negative (–) lead from the switch body

Check that the clutch pinion gear returns inward

(a) Connect the battery and ammeter to the starter as shown.(b) Check that the starter rotates smoothly and steadily withthe pinion gear moving out Check that the ammetershows the specified current

Specified current: 90 A or less at 11.5 V

ST03P–01 –

STARTING (5S–FE) STARTER

INSTALLATION

Installation is in the reverse order of removal (See page ST–5)

Star terRelay

3

25

P07171

Ohmmeter

32

5

Battery

STARTER RELAY

INSPECTION

2 REMOVE STARTER RELAY (Marking: ST)

(a) Inspect the relay continuity

(1) Using an ohmmeter, check that there is continuitybetween terminals 1 and 2

If there is no continuity, replace the relay

(2) Check that there is no continuity between terminals

3 and 5

If there is continuity, replace the relay

(b) Inspect the relay operation

(1) Apply battery positive voltage across terminals 1and 2

(2) Using an ohmmeter, check that there is continuitybetween terminals 3 and 5

If there is no continuity, replace the relay

B01274

Throttle CableClamp (A/T)

Battery Tray

CruiseControlActuatorConnector

Cruise Control Actuator

Cruise ControlCover

ClampHold Down Clamp

Starter WireStarter Connector

Starter

Battery

STARTER

COMPONENTS

Starter Housing and Clutch Assembly

Idler Gear

Bearing

Stop Collar

Pinion GearCompression SpringSpring Retainer

Steel BallReturnSpring

Magnetic SwitchAssembly

–

STARTING (1MZ–FE) STARTER

Magnetic Switch Assembly

Terminal Nut

Wave WasherTerminal Insulator

O–Ring

Contact PlateTerminalBolt

Wave WasherTerminal NutTerminal Bolt

ST01V–03 –

STARTING (1MZ–FE) STARTER

REMOVAL

2 w/ CRUISE CONTROL SYSTEM:

REMOVE CRUISE CONTROL ACTUATOR

(a) Disconnect the actuator connector and clamp

(b) Remove the 3 bolts, and disconnect the actuator with the bracket

(a) Disconnect the starter connector

(b) Remove the 2 bolts, throttle cable clamp (A/T) and starter

(c) Remove the nut, and disconnect the starter wire

Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

(a) Remove the nut, and disconnect the lead wire from themagnetic switch terminal.

ASSEMBLY AND GEAR

(a) Remove the 2 screws

Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)

(b) Remove these parts from the magnetic switch:

(1) Starter housing and clutch assembly(2) Return spring

(3) Idler gear(4) Bearing

Using a magnetic finger, remove the steel ball from the clutchshaft hole

P13528

–

STARTING (1MZ–FE) STARTER

(a) Remove the 2 screws and end cover from the field frame

Torque: 1.5 N·m (15 kgf·cm, 13 in.·lbf)

(b) Remove the O–ring from the field frame

(c) Using a screwdriver, hold the spring back and disconnectthe brush from the brush holder Disconnect the 4brushes, and remove the brush holder

NOTICE:

Check that the positive (+) lead wires are not grounded.

(a) Check the commutator for open circuit.

Using an ohmmeter, check that there is continuity tween the segments of the commutator

be-If there is no continuity between any segment, replace the mature

ar-(b) Check the commutator for ground

Using an ohmmeter, check that there is no continuity tween the commutator and armature coil core

be-If there is continuity, replace the armature

(a) Check the commutator for the dirty and burnt surfaces

If the surface is dirty or burnt, correct it with sandpaper (No.400)

or on a lathe

(b) Check for the commutator circle runout

(1) Place the commutator on V–blocks

(2) Using a dial gauge, measure the circle runout

Maximum circle runout: 0.05 mm (0.0020 in.)

If the circle runout is greater than maximum, correct it on a lathe

(c) Using vernier calipers, measure the commutator ter

diame-Standard diameter: 30.0 mm (1.181 in.) Minimum diameter: 29.0 mm (1.142 in.)

If the diameter is less than minimum, replace the armature

(d) Check that the undercut depth is clean and free of foreignmaterials Smooth out the edge

Standard undercut depth: 0.6 mm (0.024 in.) Minimum undercut depth: 0.2 mm (0.008 in.)

If the undercut depth is less than minimum, correct it with ahacksaw blade

Brush Holder Side

Field Flame Side

Length

Length

ST0019

–

STARTING (1MZ–FE) STARTER

3 INSPECT FIELD COIL

(a) Check the field coil for open circuit

Using an ohmmeter, check that there is continuity tween the lead wire and field coil brush lead

be-If there is no continuity, replace the field frame

(b) Check the field coil for ground

Using an ohmmeter, check that there is no continuity tween the field coil end and field frame

be-If there is continuity, repair or replace the field frame

Using vernier calipers, measure the brush length

Standard length: 15.5 mm (0.610 in.) Minimum length: 10.0 mm (0.394 in.)

If the length is less than minimum, replace the brush holder andfield frame

Check the brush spring load

Take the pull scale reading the instant the brush springseparates from the brush

Standard spring installed load:

1.2 kW 13.7 – 19.6 N (1.4 – 2.0 kgf, 3.0 – 4.4 lbf) 1.4 kW 17.6 – 23.5 N (1.8 – 2.4 kgf, 3.9 – 5.3 lbf)

Minimum spring installed load:

1.2 kW 9.8 N (1.0 kgf, 2.2 lbf) 1.4 kW 11.8 N (1.2 kgf, 2.6 lbf)

If the installed load is less than minimum, replace the brushsprings

No ContinuityOhmmeter

Check the brush holder insulation

Using an ohmmeter, check that there is no continuity tween the positive (+) and negative (–) brush holders

be-If there is continuity, repair or replace the brush holder

(a) Check the gear teeth on the pinion gear, idler gear andclutch assembly for wear or damage

If damaged, replace the gear or clutch assembly

If damaged, also check the ring gear of the flywheel/drive platefor wear or damage

(b) Check the clutch pinion gear

Hold the starter clutch and rotate the pinion gear clockwise, and check that it turns freely Try to rotate thepinion gear clockwise and check that it locks

counter-If necessary, replace the clutch assembly

(a) Check the pull–in coil for open circuit

Using an ohmmeter, check that there is continuity tween terminals 50 and C

be-If there is no continuity, check and replace the magnetic switch

(b) Check the hold–in coil for open circuit

Using an ohmmeter, check that there is continuity tween terminal 50 and the switch body

be-If there is no continuity, replace the magnetic switch

Turn the bearing by hand while applying inward force

If resistance is felt or the bearing sticks, replace the bearing.(See page ST–11)

(a) Disassemble the starter housing and the clutch assembly.(1) Mount a brass bar in a vise, and install the starterhousing and clutch assembly to the brass bar.

(2) Push down the pinion gear

(3) Using a plastic–faced hammer, tap down the stopcollar

(4) Using a screwdriver, pry out the snap ring

(5) Remove these parts:

Starter Housing

StarterClutch

CompressionSpring

ClutchShaft

B01230

SpringRetainer

(4) Push down the pinion gear

(5) Using snap ring pliers, install a new snap ring

(6) Using pliers, compress the snap ring

(7) Check that the snap ring fits correctly